Wall



DOC' 27, 1938- c. BATCHELLER ET AL' 2,141,96

WALL

Filed March 4, 1937 v72 Sheets-Sheet 1 ,47' TURA/EY C. BATCHELLER ET AL WALL Dec. 27, 1938.

Filed March 4, 1937 2 Sheets-Sheet 2 1 l I 7/ If I "551/ I I f I I I I /fk I I I I I Patented Dec. 27, 1938 UNITED sTATEs WALL Clements Batcheller, Glens Falls, and Frederick Heft, Troy, N. Y., assignors to Allegheny Ludlum Steel Corporation, a corporation of Pennsylvania Application March 4, 1937, Serial No. 129,002

8Claims.

Our invention relates to walls and particularly to blocks of a novel type which, in connection with other elements, are adapted to be quickly assembled in precise aligned and spaced relation l to form a wall structure.

Stainless steel is widely used for trim and decorative purposes in building construction, but large panels thereof, unless. broken up by ornamental color effects or other means, are rather 10 monotonous. Our invention, therefore, has to do with the construction of Walls of which the major portion of the exposed surface is composed of stainless steel but which is formed of separate bricks or blocks having means simulating cement ll `ioints therebetween.

One of the objects of our invention is to provide a novel type of block having its exposed face enclosed in a cap of corrosion-resisting alloy steel, andprovided with features adapting it to l be easily combined by non-skilled help with anchoring. aligning and joint simulating means to form a perfect wall structure, and without the use of cement, mortar and the like. Another object is to provide a wall of this type which will be light in weight and substantially iireproof, and

yet have practically the strength and solidity of a brick structure. A further object is to provide blocks of the character described which are easily nail penetrable whereby they may be secured 90 together in the wall assembly by nailing.

With these objects in view, our invention includes the novel elements and the combinations and arrangements thereof described below and illustrated in the accompanying drawings in which- Fig. .1 is a rear perspective view of one of the blocks or bricks used in forming our wall;

Fig. 2 is an end view of a block, partially in lection;

u Fig. 3 is a plan view of the metal blank used in forming means;

Fig'. 8 is an end view of the joint-forming means shown in Figjl;

Fig. 9 is a perspective view, looking from the rear, of a corner block;

Fig. 10 is a rear view of a. modied form of block;

Fig. 11 is an end view of the block shown in Fig. 10;

Fig. 12 is an end view of a modified block of the general type shown in Fig. l;

Fig. 13 is an enlarged fragmentary top view of the block shown in Fig. 12;

Fig. 14 is a fragmentary perspective view of a wall showing a corner construction; and

Fig. 15 is a plan view showing parallel walls which are tied together in spaced relation.

Referring to the drawings and particularly to Figs. 1, 2, 3, 4 and 14, our wall I comprises a plurality of blocks 2 arranged in horizontal courses 3, 4, etc., preferably with staggered vertical joints between the blocks. While it is to be understood that our invention is not limited to any particular size of block, for purposes of illustration, it may be assumed that the block shown in perspective in Fig. 1 is approximately the size and shape oi an ordinary pressed brick. Except where it is desirable to seal the wall against the passage of gas or liquids, it is to be understood that the blocks are laid without cement and are secured together in assembled wall relation by means of anchors and by nailing the courses together. It is therefore desirable that the material of which the block is formed should be easily nail-penetrable. It is also desirable that the wall be substantially fireproof and hence the material from which the blocks are formed should have the characteristics of nail penetrability without cracking or spalling, and also high resistance to heat.

The blocks are formed by a molding operation from a suitable plastic composition, and while it is to be understood that we are in no sense limited to the particular composition or the particular proportions of ingredients set forth, the following will be found to provide a very satisfactory block- Grams Cellulose (waste pulp bers) 750 Portland cement 'Z50 Calcined magnesite 300 Bentonite 400 Diatomaceous earth 300 Waste asbestos (C iibers) 401i` Water in a quantity sufiicient to form a plastic mixture.

This composition will form a hard product but one which has properties quite different' from those of the ordinary cement asbestos products Well known in the shingle and sheathing industry, and particularly, in that it is of comparatively light weight (only about 48 to 50 pounds per cubic foot) and that it can be sawed, drilled, nailed and otherwise worked with about the same facility as hard wood.

The exposed faces of the blocks are enclosed in rectangular caps 5 of sheet metal, preferably thin-gauge, corrosion-resistant, alloy steel, which are formed from rectangular blanks E cut to the.

shape shown in Fig. 3. 'I'he longer edges are slitted at spaced intervals, as shown at 'I, to provide tongues 8 which are bent inwardly as shown in Fig. 2 and serve to anchor the steel caps to the face of the block. The notches formed by bending in the tongues also provide openings for the egress of water from the cap during the molding of the block. The edges of the blank 8 are bent upwardly at right angles to the face of the plate along the dotted lines 9, III, II and I2 of Fig. 3 to form upstanding flanges I3, as shown in Fig. 2, which fit over and partially enclose the top, bottom and sides of the block. The blocks 2 should be molded under substantial pressure and a very rm bond is then obtained between the plastic material forming the body of the block and the metal cap or facing 5.

The tcp and bottom of each block are provided with vertically-aligned, centrally-disposed channels I4 and I5 respectively, extending parallel to the face of the block. Preferably, also, these channels are extended around the ends of the block, as shown at I6 and I'I. The top and bottom of the block are also provided with the vertically-aligned channels, I8 and I9, and 20 and 2 I, which are positioned adjacent the ends of the block. These channels are of the same depth as the channels running parallel to the face of the block and extend from the back of the block to the centrally disposed channel. These last mentioned channels, I8, I9, and 2|, are at the same distance from the ends of the block as the centrally disposed channels are from the face of the block.

In Fig. 9 we have shown a corner block having longitudinally extending grooves or channels 22 in the top and bottom thereof which are similar to the channels I4 and I5 in the block shown in Fig.v 1. Here, however, both the face 23 of the corner block and one end 24 are enclosed in a metal cap 25 similar to the metal cap 5. Vertically aligned cross channels,'26 and 21, and 28 and 29, similar to the channels, I8 and I9, and 2l and 2|, are provided and extend from the back of the block to the centrally disposed channels.

Referring particularly to Figs. 4, 5, 6, 7, 8, 9 and 14, a suitable foundation 30, such for example as a cast or rolled section, is provided for our wall. The first horizontal layer of blocks is secured thereto by`means of bolts or cap screws 3| which are threaded into the base 30 as shown at I2. The base or foundation is provided along the top with a centrally-disposed, longitudinally-extending boss 33 which is adapted closely to interfit with the grooves or channels I5 in the bottoms of the first course of blocks. The height of the boss 33 is somewhat greater than the depth of the channels I5 so that the bottoms of the blocks at the front and back are spaced above the general level of the base 30 to permit the insertion therebetween of strips 34 and 95. These strips may be of the same material as that of which the blocks are formed and are positioned in the spaces between the bottoms of the blocks and the top of the foundation to simulate cement joints. The exposed edges of these strips may be appropriately colored to simulate colored mortar. After the ilrst course of blocks is secured in place, anchoring strips Il are po sitioned in the channels I4 in the tops of the ilrst course of blocks. These anchoring strips may be made of the same material as the blocks and of a width designed to interflt closely with the channels I4 in the top of the first course and the channels I5 in the bottom of the second course of blocks. The vertical thickness of these strips is substantially equal to twice the depth oi' the channels in the blocks plus the thickness of the joint simulating strips 34 and 35. Where the anchoring strips 3l overlie the bolts or cap screws 8|, they may be recessed to receive the heads or nuts 38 therein. Vertical cement joints between the blocks in each course are simulated by the plates 99 which may be of the same material as the blocks and anchoring strips. These plates are of the same thickness as the strips 34 and Il and of the same height as the blocks. They are provided at the top and bottom central portions with notches 40 and 4I adapted to intert closely with the anchoring strips 3l. In Fig. 7, the dotdash line 42 is the geometrical center of the plate 39 and, vit will be observed that the notches 48 and 4| are not precisely centered on this line. The length of the plates 29 is less than the width of the bricks so that the edges of the plates when positioned in the.wall set somewhat back from the metal face. The purpose of the asymmetrical disposition of the notches 40 and 4I with respect to the center of the plate is to permit the wall builder to have a choice of two distances to which the vertical joints may be set back from the face of the wall. The vertical edges 43 and 44 may be colored as' shown at 45 in the same manner as described for the edges of the strips simulating the horizontal joints. Except for the horizontal joint between the first horizontal course and the foundation, the anchoring strips andthe horizontal, joint-simulating strips may be formed in one unit 46, as shown in Fig. 5.

At the corners of the wall, corner blocks of the type shown in Fig. 9 are employed and it will be apparent from a consideration of the block shown lin Fig. 9 and the wall shown in Fig. 14 that only one type of corner block is necessary because the top and bottom surfaces of the blocks are identical and they may be used either side up. The anchoring strips 39 extend into the channels 22, 2l and 2'I inthe corner blocks and secure them in perfectly aligned. relation with the other courses. The horizontal, joint-simulatingl strips at the corners are preferably made angular, as shown at in Fig. 6. After each course is laid, the next succeeding course, including the anchoring strips, may be readily nailed thereto so that a very solid wall structure is obtained.

The vertically aligned cross channels I8 and I9, and 20 and 2| also vfunction to receive H- Shaped anchoring elements 4l for securing together parallel walls 48 and 49 as shown in Fig. 15.

The channels I6 and II in the ends of the block are for the purpose of permitting the blocks to be laid vertically as well as horizontally and yet cooperate with the anchoring strips 39.

Where it is desirable to seal the wall against the passage of gasses or liquids, we provide the blocks with additional small grooves 5I extending entirely around the rear portion thereof as shown in Figs. 12 and 13. These grooves may be filled with a suitable sealing material.

While for most uses our blocks will probably made of the general size and shape of pressed Figs. 10 and 11 we have shown a block 52 having a square face enclosed in a metal cap 53 and provided with a centrally disposed channel 54 extendingentirely around the block and which is adapted to intert with the anchoring strips 3l. In blocks of large size, such for example as those Shown in lrigs. 10 and 11, portions 55 may be made hollow to save material and also to lighten the block.

Fromdthe foregoing it will be apparent that skilled labor is not necessary to construct our wall. The blocks are automatically positioned and maintained in perfectly aligned relation by means of the anchoring strips, and because the material of which the blocks, and the anchoring and joint-simulating strips are formed, permits them to be readily nailed together and also to be sawed and otherwise worked, a perfect and very solid wall can be quickly constructed by anyone.

Half-bricks can be made for finishing the ends of the wall, and by varying the thickness of the joints almost any space can be completely filled with our blocks.

Although substantially only the faces of our blocks are covered with metal, walls made therefrom nevertheless appear to be made from solid metal blocks because the sheet metal facing extends around the edges' of the face and far enough. over the top, bottom and sides of the block so that its inner edges are concealed by the joint-simulating strips.

While we have described our invention in its prefered embodiment, it is to be understood that the words Which we have used are words of description rather than of limitation. Hence, changes within the purview of the appended claims may be made without departing from the true scope and spirit of our invention in its broader aspects.

What we claim is:

l. A wall comprising a plurality of blocks provided with channels therein and arranged in horizontal courses, means interiitting said channels in a plurality of blocks in each of two vertically adjacent courses for maintaining said blocks in aligned relation and said courses in vertically spaced relation, and means simulating cement joints positioned between said courses.

2. In a wall, the combination with a plurality of blocks provided with channels therein and arranged in two, adjacent, horizontal courses, of an anchoring strip positioned between said courses and cooperating in intertting relation with said channels in a plurality of blocks in each of said courses to simulate a cement joint between said courses and to maintain said blocks in spaced aligned relation, and means cooperating in intertted relation with said strips to simulate vertical joints between said blocks and maintain them in horizontally spaced relation.

3. A building block having a front face and .comprising a rectangular, prism-like body provided with a centrally disposed groove therein extending entirely around said body and parallel to said face and having oppositely disposed grooves in the top and bottomthereof and adjacent eaclr'end of said block extending from the back thereof to said centrally disposed groove.

4. A building block comprising a rectangular, prism-like body having a front face and provided .with a centrally disposed groove extending entire.-

ly around the body thereof parallel to said face, and having oppositely disposed grooves in the top and bottom thereof and adjacent each end of said block extending from the back thereof to said centrally disposed groove; the distance of said opposite disposed grooves from the ends of said block being the same as thedistance of the centrally disposed groove from the face of said block.

5. A wall comprising a plurality of rectangular blocks arranged in horizontal courses and provided in the top and bottom thereof with a longitudinally extending channel, anchoring strips somewhat thicker than twice thedepth of said channels and positioned therein between adjacent horizontal courses of said blocks, whereby said courses are vertically spaced from each other, strips simulating cement joints positioned between said courses, a'nd spacing means cooperating with said anchoring strips and positioned between 'adjacent blocks in said horizontal courses to simulate cement joints.

6. A wall comprising a plurality of rectangular blocks arranged in horizontal courses and provided on the top and bottom with aligned, longitudinally-extending, centrally disposed channels; anchoring strips positioned between said courses comprising central, comparatively thick portions closely intertting with said channels in the bottom of the course above and with said channels in the top of the course below, and comparatively thin side portions extending toward the face of said wall to simulate cement joints between said courses, and spacing plates interfitting with the centralportions of said anchoring strips between adjacent blocks in each of said courses to simulate vertical cement joints.

7. In a wall comprising a plurality of rectangular blocks arranged in horizontal courses and provided in the top and bottom with verticallyaligned channels extending parallel to the face of said wall; a corner construction comprising rectangular corner blocks provided in the top and bottom with vertically-aligned, angularly disposed A`channels extend-ing parallel to the exposed sides and ends, respectively, of said blocks, anchoring strips somewhat thicker than twice the depthv of said channels closely iitted therein between said corner blocks in adjacent horizontal courses whereby said corner blocks are maintained in vertically spaced and aligned relation, and plates simulating cement joints positioned in the spaces between said blocks and interiitting with said anchoring strips. y r

' 8. In a Wall, the combination with a plurality of blocks provided with channels therein and arranged in two, adjacent, horizontal courses, of an anchoring strip positioned between said courses; said strip being provided with a central portion cooperatingin intertting relation with said channels in a plurality of blocks in each of said courses, and with a portion extending toward the face of said wall to simulate a. cement joint between said courses.

CLEMENTS BATCHELLER. FREDERICK HEFT.

CTX 

